granada don
Active member
- Joined
- May 20, 2013
- Messages
- 34
Another good point about getting the concrete done , the sooner you can get to building your street gasser Willy's
G Don
G Don
The Concrete Underground
- Thread starter ConCretin
- Start date
Mr onetwo
Well-known member
Great to hear you are on track.All work and no play makes Jack a dull(and divorced) boy!
Ask me how I know.
Ask me how I know.Panel Dan
Well-known member
Somehow I'd missed this thread previously. This is absolutely amazing. Someone said before that they have seen spice rack threads with less progress, and I completely agree. In the time you've spent building this incredible house, I have built two sets of shelves and two workbenches that I'm going to tear apart again and replace with steevo benches.
I can't wait to see this build progress, especially into the workshop and garage side of things as I am intrigued to see what level of detail you go to with tooling / storage / machinery etc etc etc...
Cheers!
I can't wait to see this build progress, especially into the workshop and garage side of things as I am intrigued to see what level of detail you go to with tooling / storage / machinery etc etc etc...
Cheers!
Hornman
Well-known member
I have really enjoyed this thread, thank you. I have wanted to pour me a house for a long time. Have you estimated how long it would have taken to get to where you are now if it was a customer's project?
Oggy
Well-known member
I'm sure that would've depended upon the customer's budget. I've always been told / said there are 3 ways to get construction done, 1)right, 2)quick, 3)cheap; But you can only pick 2. I would imagine with LL #1 would be a given.
The good news is that this update ends with the last big structural concrete placement. The bad news is that........actually there is no bad news cause the basic structure of the house if officially DONE. We've still got the chimney, some parapet walls and some misc stairs and pad to do but the worst is behind us.
Here's a shot of the completed upper roof deck edge beams;
The completed lower roof;
This is one of the beams that frame the opening for the skylight over the lift;
With formwork and reinforcing complete, we are ready to place. I intended to place FRiday but a bad weather forecast lead to a postponement until Saturday morning.
As with past LiteDeck placements, we are using a 4000 psi 3/8 mix with a mid range water reducer. This gives us a nice workable 5-6" slump with minimal water.
We started by filling in the bottom 6 to 7". This gives a chance to vibrate thoroughly to make sure the concrete works it's way into all the cracks and crevasses. We then go back and place a second lift for the finishers.
The guys on the left are building wet pads that they will screed form using a laser to determine grade. The guy on the right is bull floating the concrete they have already screeded.
If it looks like they're wading back into concrete that has already been bull floated, it's because they are. The bull float operator saw something he didn't like so he had them re-screed an area. I'm lucky to have such dedicated people helping me.
It wasn't long before they had the upper roof done.
The lower roof went much the same. After the slab had set enough, I covered it with hydracure sheeting and we were done.
With this placement complete, I finally have all my window openings done. Now I need to focus on detailing all the openings and field measure for windows. I'm about two months behind schedule and am going to be tight on getting the place buttoned up by cold weather.
Here's a shot of the completed upper roof deck edge beams;
The completed lower roof;
This is one of the beams that frame the opening for the skylight over the lift;
With formwork and reinforcing complete, we are ready to place. I intended to place FRiday but a bad weather forecast lead to a postponement until Saturday morning.
As with past LiteDeck placements, we are using a 4000 psi 3/8 mix with a mid range water reducer. This gives us a nice workable 5-6" slump with minimal water.
We started by filling in the bottom 6 to 7". This gives a chance to vibrate thoroughly to make sure the concrete works it's way into all the cracks and crevasses. We then go back and place a second lift for the finishers.
The guys on the left are building wet pads that they will screed form using a laser to determine grade. The guy on the right is bull floating the concrete they have already screeded.
If it looks like they're wading back into concrete that has already been bull floated, it's because they are. The bull float operator saw something he didn't like so he had them re-screed an area. I'm lucky to have such dedicated people helping me.
It wasn't long before they had the upper roof done.
The lower roof went much the same. After the slab had set enough, I covered it with hydracure sheeting and we were done.
With this placement complete, I finally have all my window openings done. Now I need to focus on detailing all the openings and field measure for windows. I'm about two months behind schedule and am going to be tight on getting the place buttoned up by cold weather.
Last edited:
gipraw
Well-known member
Nice. I bet you are having plenty of mixed feelings right now. That is a major hurdle completed.
I'm glad your enjoying the thread Hornman. I haven't thought about it in those terms but I'm sure you could build a very similar house for less cost using more traditional methods. Even though I'm in the business this thing is expensive. I'm not sure anybody would pay me to build one for them $$$$
Actually I am. I'm sure I'll look back on the experience fondly but right now I just want to finish the damn thing.
The floors will be vein cut limestone throughout. Ironically, I'm not a big fan of decorative concrete.
granada don
Active member
- Joined
- May 20, 2013
- Messages
- 34
Hi LL
I was wondering how you will finish off the exposed foam you see from the bottom side of the concrete 2 nd floor?
In the 70's Bob Norskogg had his race boat shop in Van Nuys, his shop floor was just very smooth waxed & buffed concrete and boy did it look good.
That was before they got the Epoxy worked out to hold up better like they have now days
Thanks, Don
I was wondering how you will finish off the exposed foam you see from the bottom side of the concrete 2 nd floor?
In the 70's Bob Norskogg had his race boat shop in Van Nuys, his shop floor was just very smooth waxed & buffed concrete and boy did it look good.
That was before they got the Epoxy worked out to hold up better like they have now days
Thanks, Don
Thedoc14
Well-known member
LL three cheers mate you have made a great achievement in getting this far with all the usual hickups.
You can sit back for a day or 2 and have a look at what you have, and what lies ahead...
You can sit back for a day or 2 and have a look at what you have, and what lies ahead...
Omphaloskeptic
Well-known member
Congratulations on reaching this MAJOR milestone!
With winter just around the corner in your neck of the woods, what do you have to do to protect the roof surface from freeze damage (spalling?)?
Here's hoping your window measurements (magically) match your suppliers on-hand stock of standard spec glazing!
With winter just around the corner in your neck of the woods, what do you have to do to protect the roof surface from freeze damage (spalling?)?
Here's hoping your window measurements (magically) match your suppliers on-hand stock of standard spec glazing!
Oggy
Well-known member
It's really looking good, and I"m sure we're all glad to see the progress again.
I may have missed something, but why the LVL's for the windows instead of using a regular 2x? The only thing I can think of is that it's a more stable (less expansion/contraction) product and that it's also straight.
I may have missed something, but why the LVL's for the windows instead of using a regular 2x? The only thing I can think of is that it's a more stable (less expansion/contraction) product and that it's also straight.
almost spilled my coffee on this one
Panel Dan
Well-known member
Same thing happened here.
Omphaloskeptic
Well-known member
Sorry about the spilled coffee guys, I was just trying to be overly optimistic for the OP's sake. lol
congrats on this milestone, building a super-villain villa/lair can be such a major pita, but you'll love it for decades to come when you're done!
also loving that you're not quite into decorative concrete...go figure, haha
so excited to see things move forward, you did so much work by now and this thread is super-awesome...but honestly, i think it is now that the fun part begins. all the small details, the finishing, seeing that ugly-duckling (naked concrete house, surrounded by buildsite-charme) turn into a swan (the finished house)...as far as i am concerned, i can't wait! this is super-awesome already and yet will keep getting so much better, post by post...
also loving that you're not quite into decorative concrete...go figure, haha
so excited to see things move forward, you did so much work by now and this thread is super-awesome...but honestly, i think it is now that the fun part begins. all the small details, the finishing, seeing that ugly-duckling (naked concrete house, surrounded by buildsite-charme) turn into a swan (the finished house)...as far as i am concerned, i can't wait! this is super-awesome already and yet will keep getting so much better, post by post...
Simon.
Active member
Concrete is beautiful!!
iPhone1
Active member
absolutely stunning, I especially love the location & design.
magnumleigh
Member
I just caught up and.....WOW! It's great having a fly-on-the-wall view of the entire process, your construction methods and also your personal point of view/impression/enthusiasm.
And that view........ Surely every time you're getting fed up or tired of working that just has to inspire you.
Ps. When is Tony Stark collecting the keys?
And that view........ Surely every time you're getting fed up or tired of working that just has to inspire you.
Ps. When is Tony Stark collecting the keys?
mike_81
Well-known member
maybe you could rent out the place for the next movie involving iron man!
If finished and combined with Steel, Wood, Glass or other materials..and done right... I agree! But a raw concrete structure just does not compare to the finished product, imho
P.S.: might not have been the best choice of words, regardless of the beauty of a raw concrete structure this whole build is just very awesome. the scale, the layout of the house and garage + the dock, the surroundings...this is epic already, either way!!
It's been a bit longer between updates than I'd hoped but I've finally got enough content to justify one. We've had a couple more milestones. the first of which is the return of all the rented shoring;
We're about two and a half months behind schedule and that means two and a half months of extra rent. Luckily my supplier is using me right so it's not too bad a hit.
The other major milestone was the field measuring of all our windows and doors. Given the nature of the structure and the cost of the glazing, we felt it was prudent to field measure all the opening before ordering the doors and windows. We've been working hard to finish framing all the RO's.
Here's the openings on the back of the house in the Prep Kitchen. We built up lumber posts to match the dimensions of the steel support posts. They will all get wrapped in metal that matches the windows.
Here's the front of the second floor;
and the rear;
the master bedroom cantilever;
We've also started working on the fascias and roof blocking. The front elevation is starting to take shape. You might notice that we've also started forming the chimney
Here's another view of the chimney;
Though it generated a bit of controversy, I still plan to form the 'flues' with 10" PVC Pipe. One flue is for the gas fireplace vent and the other for an exhaust vent for the gas grille. Neither will expose the PVC to unusually high temps in normal operation.
We've also started work on the parapets over the Garage and Master Bedroom. This is the parapet on the garage roof;
The roof system consists of 2" of rigid insulation covered by a tapered insulation that starts at 1/2" thickness and tapers at 1/4" per foot until it meets the back of the parapet. The membrane roof sheet and insulation is held in place by 1 1/2" of stone ballast.
Here's a closer shot of the parapet over the Master Bedroom. We'll install a cap consisting of two layers of 3/4" Advantech plywood to provide a nailing surface for roofing and flashing.
I'll throw in a couple random shots I thought you might find interesting. The view down the front of the garage;
And a shot from the stair landing at the Guest Bedroom looking past the two story AC wall;
I plan to build some kind of suspended AC staircase here that I want to be a real focal point of the home.
As we finish up the concrete work and finally get the site cleaned up, it's time to start finishing up the site work. In preparation, we've brought back the 'big iron'
Before I close, I'd like to take a moment to brag up my concrete crew. As any of you who have done concrete work will know, it is very difficult to maintain tight tolerances - the stuff is damn heavy and tends to push things around.
The window company came out to measure our openings with lasers and edm's and I was amazed how well we'd done. We were literally chasing 1/8's. The openings were essentially perfect. I'm not sure you could do any better with lumber framing.
I am fortunate to have such skilled and conscientious people working for me.
We're about two and a half months behind schedule and that means two and a half months of extra rent. Luckily my supplier is using me right so it's not too bad a hit.
The other major milestone was the field measuring of all our windows and doors. Given the nature of the structure and the cost of the glazing, we felt it was prudent to field measure all the opening before ordering the doors and windows. We've been working hard to finish framing all the RO's.
Here's the openings on the back of the house in the Prep Kitchen. We built up lumber posts to match the dimensions of the steel support posts. They will all get wrapped in metal that matches the windows.
Here's the front of the second floor;
and the rear;
the master bedroom cantilever;
We've also started working on the fascias and roof blocking. The front elevation is starting to take shape. You might notice that we've also started forming the chimney
Here's another view of the chimney;
Though it generated a bit of controversy, I still plan to form the 'flues' with 10" PVC Pipe. One flue is for the gas fireplace vent and the other for an exhaust vent for the gas grille. Neither will expose the PVC to unusually high temps in normal operation.
We've also started work on the parapets over the Garage and Master Bedroom. This is the parapet on the garage roof;
The roof system consists of 2" of rigid insulation covered by a tapered insulation that starts at 1/2" thickness and tapers at 1/4" per foot until it meets the back of the parapet. The membrane roof sheet and insulation is held in place by 1 1/2" of stone ballast.
Here's a closer shot of the parapet over the Master Bedroom. We'll install a cap consisting of two layers of 3/4" Advantech plywood to provide a nailing surface for roofing and flashing.
I'll throw in a couple random shots I thought you might find interesting. The view down the front of the garage;
And a shot from the stair landing at the Guest Bedroom looking past the two story AC wall;
I plan to build some kind of suspended AC staircase here that I want to be a real focal point of the home.
As we finish up the concrete work and finally get the site cleaned up, it's time to start finishing up the site work. In preparation, we've brought back the 'big iron'
Before I close, I'd like to take a moment to brag up my concrete crew. As any of you who have done concrete work will know, it is very difficult to maintain tight tolerances - the stuff is damn heavy and tends to push things around.
The window company came out to measure our openings with lasers and edm's and I was amazed how well we'd done. We were literally chasing 1/8's. The openings were essentially perfect. I'm not sure you could do any better with lumber framing.
I am fortunate to have such skilled and conscientious people working for me.
Last edited:
Thanks to all for the encouraging comments.
We're installing 1 1/2" of strapping and then sheetrock. Kinda boring huh?
We should have the roof on before snow flies..............I hope!
That would be a miracle indeed. Unfortunately windows are 10 weeks out.
You got it right. The LVL's are more stable and provide a bit more strength than lumber. Their purpose is to provide some structure to mull the door/window units together and help resist wind load
Cheers everybody.
We're installing 1 1/2" of strapping and then sheetrock. Kinda boring huh?
We should have the roof on before snow flies..............I hope!
That would be a miracle indeed. Unfortunately windows are 10 weeks out.
You got it right. The LVL's are more stable and provide a bit more strength than lumber. Their purpose is to provide some structure to mull the door/window units together and help resist wind load
Cheers everybody.
Last edited:
el Pedro
Well-known member
Love seeing updates on this and absolutely love the design. It ties in so well with the surroundings.
What will you do to finish off the roof? (not sure if it's been mentioned or not). Will you use tar and pebbles or finish it off with plants for extra insulation? Also being your in a snow area how does the snow 'run off'?
What will you do to finish off the roof? (not sure if it's been mentioned or not). Will you use tar and pebbles or finish it off with plants for extra insulation? Also being your in a snow area how does the snow 'run off'?
SiGmA_X
Well-known member
Yet another milestone! You and your crew are obviously damn good, nice work. I feel like a broken record, but man, I'm in awe constantly.
My dad had a question you may have an answer for. What do you do for the thermal break around the floor slab? He's in the early planning stages of an addition at our family beach cabin, including an master suite and maybe a guest room/home office. The house is a 1960's single slab and CMU, mostly hollow with minimal rebar from what we discovered when we knocked out the front wall/windows and put in a 16' slider unit! Expansion is going to be another slab, this one with insulation underslab and either ICF, CMU + SIPS (single sided) or CMU + EPS. They're still kicking around the idea of stick building the expansion, but that is less likely. Either way, what is your prefered method of thermal break around the edges of slab? If you want me to take it to PM or if you don't have time, that's totally fine!
Keep up the great work LL, and thanks!
My dad had a question you may have an answer for. What do you do for the thermal break around the floor slab? He's in the early planning stages of an addition at our family beach cabin, including an master suite and maybe a guest room/home office. The house is a 1960's single slab and CMU, mostly hollow with minimal rebar from what we discovered when we knocked out the front wall/windows and put in a 16' slider unit! Expansion is going to be another slab, this one with insulation underslab and either ICF, CMU + SIPS (single sided) or CMU + EPS. They're still kicking around the idea of stick building the expansion, but that is less likely. Either way, what is your prefered method of thermal break around the edges of slab? If you want me to take it to PM or if you don't have time, that's totally fine!
Keep up the great work LL, and thanks!
CoconutPete
Well-known member
Wow great update.
I apologize if this in formation is in the thread, but what does AC stand for in "AC wall"?
I apologize if this in formation is in the thread, but what does AC stand for in "AC wall"?
Thedoc14
Well-known member
You would struggle to get Carpenters (run of the mill Framers) to get you that close of a tolerance.
Full Kudos to you and your crew you have done a Spectacular job that will last the years to come. 
Full Kudos to you and your crew you have done a Spectacular job that will last the years to come.
Boosted1
Well-known member
Wow LLWillysfan! That's a huge update. I enjoyed looking at the pics. Impressive.
I know I sound like a broken record but thanks for the positive comments. It means a lot to me that guys like you are enjoying the thread.
The roof will be an EPDM membrane over tapered insulation that creates a 1/4" per foot pitch. The membrane and insulation will be held in place with stone ballast. The roof structure is designed to support the inevitable snow build up - though the wind tends to clear most of it away.
We have been very careful to isolate the heated slabs with a minimum of 2" of rigid insulation. Because of the complexity of the structure, it's been challenging but we've managed pretty well.
You and your Dad are smart to make this a priority. Good luck with your project and be sure to post some pics.
The roof will be an EPDM membrane over tapered insulation that creates a 1/4" per foot pitch. The membrane and insulation will be held in place with stone ballast. The roof structure is designed to support the inevitable snow build up - though the wind tends to clear most of it away.
We have been very careful to isolate the heated slabs with a minimum of 2" of rigid insulation. Because of the complexity of the structure, it's been challenging but we've managed pretty well.
You and your Dad are smart to make this a priority. Good luck with your project and be sure to post some pics.
tinkergeek
Well-known member
- Joined
- Dec 26, 2012
- Messages
- 107
Amazing project. Thoroughly enjoyed all that you shared. Your posts must have taken a great deal time over the course of the project but your readers all agree it was great reading. Sure revealed the hidden skills and complexity of concrete work. A real learning experience. Particularly appreciated the need to constantly solve new problems and adapt to crazy weather situations. The professionals can roll with the situation.
Only 1/8" over such a complicated project, weather, and time itself, that's amazing. Maybe it's time for another crew photo op in recognition of their work and to mark the end of this phase.
Only 1/8" over such a complicated project, weather, and time itself, that's amazing. Maybe it's time for another crew photo op in recognition of their work and to mark the end of this phase.
What do you expect Doug, it's easy to tell that you lead by example. The day that you started the pour by yourself and your guys hauled *** to get there, shows they like working for you. . . . . roll the Keystone Kops music. . .
Cemoto
Well-known member
1/8" is perfect and you have the rights to brag!
Damn fine weather this week eh?
The wife and I are out at York.
Regards,
.
Damn fine weather this week eh?
The wife and I are out at York.
Regards,
.
We had a pretty good week and placed some more concrete yesterday. First we had to finish up the formwork for the chimney;
Here's a shot from the top
I'd love to use my conveyor to place some of the this concrete but the boom won't bend like this;
When placing tall narrow forms like this, you have to be careful with your lifts and placement rate. It's very easy to bring the concrete up too fast. With light duty formwork like this, you don;t want to exceed about 7' hour
We're also very careful to vibrate 6" or so into the previous lift and no more. The ******** 'liquifies' the concrete and increases the pressure on the forms.
We also placed the roof parapets;
And a little concrete curb at one of the window openings;
The remaining concrete is down to some entry stairs and aprons - plus the AC stairs to the Guest Bedroom, which I won't be able to tackle for w awhile.
Next we're moving on to preparations for stucco. The schedule and budget required a change from the cement board rain screen we were originally going to use. My wife was never really sold on the rain screen anyway.
There're scheduled to start in a couple weeks and I've got a lot to do before then including building the porch roof.
Here's a shot from the top
I'd love to use my conveyor to place some of the this concrete but the boom won't bend like this;
When placing tall narrow forms like this, you have to be careful with your lifts and placement rate. It's very easy to bring the concrete up too fast. With light duty formwork like this, you don;t want to exceed about 7' hour
We're also very careful to vibrate 6" or so into the previous lift and no more. The ******** 'liquifies' the concrete and increases the pressure on the forms.
We also placed the roof parapets;
And a little concrete curb at one of the window openings;
The remaining concrete is down to some entry stairs and aprons - plus the AC stairs to the Guest Bedroom, which I won't be able to tackle for w awhile.
Next we're moving on to preparations for stucco. The schedule and budget required a change from the cement board rain screen we were originally going to use. My wife was never really sold on the rain screen anyway.
There're scheduled to start in a couple weeks and I've got a lot to do before then including building the porch roof.
Last edited: